CN111511626B

CN111511626B - Bogie frame for aluminium cast rail vehicle

Info

Publication number: CN111511626B
Application number: CN201880080166.5A
Authority: CN
Inventors: L·托尼
Original assignee: L Tuoni
Current assignee: L Tuoni
Priority date: 2017-12-18
Filing date: 2018-12-17
Publication date: 2023-08-22
Anticipated expiration: 2038-12-17
Also published as: US11702118B2; EP3727989A1; ES2909967T3; CN111511626A; RU2757100C1; US20240059329A1; EP3727989B1; PL3727989T3; MX2020006484A; DE202017107670U1; WO2019121524A1; US20210070328A1; CA3085379A1

Abstract

The invention relates to a bogie frame (1) for a rail vehicle having at least two sets of wheels, comprising two longitudinal beams (3) extending parallel to each other through bearings, one or more transverse beams (2) connected to the longitudinal beams (3) and a receiving area (5) for functional elements, wherein the bogie frame (1) is formed in sand mould casting from an aluminium alloy with a cavity profile and is integrally formed as a casting, wherein a cavity (10) is provided in the casting and is stabilized by ribs (8, 9). The invention further relates to a method of manufacturing such a bogie frame and to a rail vehicle provided with such a bogie frame.

Description

Bogie frame for aluminium cast rail vehicle

Technical Field

The present invention relates to a bogie frame according to claim 1 for a railway vehicle having at least two sets of wheels.

Background

The invention relates to a drive for a rail vehicle according to claim 1, which is formed by a bogie, wherein the wheel sets are mounted in a frame rotatable relative to the carriage. The bogie has various construction modes and designs. The old bogies have gooseneck bogies or are made of gellitzAnd Minden-Daozz (Minden-Deutz). The chassis of the bogie must be able to withstand high loads and consist of at least one transverse beam on which the pivot of the car body is supported. Two longitudinal beams arranged parallel to each other are fixed to the ends of the transverse beam. The longitudinal beam is connected to the four wheel sets of the bogie via suspension means. The suspension means are constituted by different spring sets mounted coaxially. Such a bullet nowadaysThe spring system is typically composed of a secondary suspension and a primary suspension. Such bogies are described, for example, in EP 1 150 872 B1,EP 1 637 425 A2,US 4,258,629 A,DE 198 19 412 C1 or EP 2 165 913 B1.

In a typical embodiment, a larger railway car is configured with two bogies, each bogie having two sets of wheels. However, it is known in these embodiments that the number of axles and wheel sets that can be used per truck may vary depending on the configuration of the railway car. The number of wheelsets may be adjusted according to the desired and allowed vehicle load.

All other parts, such as wheel sets, springs and shock absorbers, are fixed to the bogie frame. Bogie frames are typically composed of welded steel structures, in part, the frames also being cast from steel.

The bogie also includes a fulcrum pin (also referred to as a pivot disc) that connects the bogie to the car, and also generally transfers longitudinal forces between the car and the bogie. The bogie moves about a vertical axis formed by the fulcrum pins.

The conventional bogie frames are very heavy and have high residual stresses and are susceptible to corrosion if made of steel. The welded structure of steel plates and steel pipes is very complicated in its manufacture and thus is costly. Welded truck frames also contain welded joints, which can interrupt stresses and can crack under heavy loads. In the case of high load components such as bogie frames, these welded joints on the welded structure may be particularly susceptible to mechanical loads, which ultimately reduce the mechanical load capacity of the component.

Furthermore, previously known bogie frames also result in strong driving noise which can only be reduced by means of complex damping devices.

Disclosure of Invention

In order to avoid these drawbacks, the object of the present invention is to provide a bogie frame for a railway vehicle having at least two sets of wheels, which has a lower weight and a significantly reduced driving noise with respect to a steel structure. Preferably about 40% weight reduction relative to steel structure. The weight reduction is dependent on the respective embodiment.

This object is achieved by a bogie frame having the features of claim 1 and a method of manufacturing such a bogie frame. Preferred embodiments are in the dependent claims.

The bogie frame according to the invention is intended for a railway vehicle having at least two sets of wheels, consisting of two longitudinal beams extending parallel to each other through bearings, which longitudinal beams are interconnected with one or more transverse beams. In a variant, the longitudinal beams and the transverse beams may be bolted or welded together, depending on the function. Inside the bogie frame there is a receiving area for connecting the fulcrum pin with other functional elements. The present invention now provides a bogie frame which is preferably manufactured in a sand mould casting process from an aluminium alloy and integrally as a casting. The cavity or hollow profile created during this process will be stabilized by the ribs.

It is preferred that the bogie frame of the present invention is manufactured in aluminium-sand mould casting. The mould is preferably manufactured by means of a mould device during manual moulding or during pellet moulding. This is a "lost pattern" because after casting the pattern or core made of chemically or clay bonded sand must be destroyed.

Typical functional elements in a railway vehicle bogie refer to elements for the safe running of a railway vehicle on a rail body. Like the bogie frame, primary and secondary suspensions, shock absorbers, braking systems, wheel sets, and motors and drives according to embodiments.

The invention relates to a bogie frame made of aluminium alloy, which is integrally formed as a complete casting, receives the force transmission and load of functional elements and ensures safe operation. The bogie frame can thus be used as a single casting, which replaces the steel structure currently known in bogies for rail vehicles. This avoids cumbersome welding work and stress sensitive welds. In addition, by making the bogie frame as an integral manufacturing process made of aluminum alloy, the cost can be reduced by about 30 to 50%. This is a great advantage over known steel bogie frames. The inspection interval for testing the continued operation of the component on the stress crack can be adjusted based on the calculation results, the continuous shock test and the in-service inspection results.

The technical parameters of the bogie frames manufactured by means of sand mould casting are required to be optimally matched to the mechanical load and the requirements of continuous operation. The cavities of the bogie frame are preferably made of chemically bonded sand, the sand core being mounted in a mould. The castings are barely stressed by the heat treatment at T6 during the manufacturing process. The residual stresses may be ignored by the heat treatment during the manufacturing process. The structural and mechanical properties of the aluminum alloy may result in a weight saving of about 40%.

The desired stability is ensured by the cavity formed inside the casting and the ribs provided therein.

The hollow space of the longitudinal beam and/or the transverse beam is preferably a gas reservoir which can be used as a functional element of a rail vehicle. This has considerable advantages over the gas reserves in the known bogie frames, for example for cross-pieces or gas reserves made of steel plates and welded for this purpose in addition. Through the hollow space of the bogie frame, gas reservoirs can be achieved which can completely replace this function. Thereby eliminating the use of a complicated construction of a cross member or other form of gas reservoir. Of course, it must be ensured that the cavity provided for the bogie frame is airtight and checked according to technical specifications.

In a preferred variant, ribs are provided on the underside of the danger zone to prevent broken stones. This area must be protected from broken stones, since this is on the underside of the bogie frame and the suction of broken stones in the direction of travel must be prevented. The ribs are at least 20mm apart and at least 5mm thick.

In a preferred embodiment, a layer of rubber is provided between the ribs, preferably by spraying a layer at least 5mm thick. The steel plate bolted under the train can be dispensed with by applying a rubber layer, which reveals further economic and operational advantages of the bogie frame of the present invention.

Preferably, the aluminum alloy is composed of an alloy of aluminum, silicon and magnesium. Manganese, copper or zinc may also optionally be added without corrosion of the surface and protected with an elastic wet paint. However, it is preferred that the copper and zinc content be kept low to avoid tarnishing. The aluminum alloy of the present invention enables castings to have high mechanical properties and to be resistant to corrosion. The casting AC-AlSi7Mg0,3ST6 of the present invention is preferably used. The casting itself is uniformly constructed and is capable of withstanding stresses. In a preferred embodiment, the casting is provided with a resilient surface protection that protects it from corrosion.

The load and force of the primary suspension on the wheelset is preferably introduced into the bogie frame over a large area and widely through a hat-shaped insert made of non-corrosive steel. The advantages of the supporting effect in the assembly are thus better utilized and local overloads at the supporting arm are avoided. The protruding portion of the cap insert transfers the load to the entire diameter and the entire surface. The aluminum casting of the invention can greatly reduce noise and driving noise. By the choice of ribs inside the cavity, the function can be combined effectively with stability. The ribs are designed in various shapes and thicknesses according to the calculated stress pattern.

The invention also relates to a method for manufacturing a bogie frame for a rail vehicle with at least two sets of wheels, comprising two longitudinal beams extending parallel to each other through bearings, and a transverse beam connected to the longitudinal beams and implemented as a gas reservoir. The longitudinal beams and the transverse beams may be designed to accommodate functional elements. According to the invention, the bogie frame is constructed from an aluminum alloy as a complete casting in sand mould casting, with a plurality of cavities stabilized by ribs. It is preferred that the cavity is made of chemically bonded sand and has a form in which a sand core is present. In a preferred variant, the cavities of both the longitudinal beams and/or of the transverse beams are built up in the form of gas reservoirs. In a further preferred embodiment variant, the casting is constructed uniformly and stress-free and is preferably provided with elastic surface protection. Surface protection without thermal loading on the component and a very low proportion of residual stress ensure optimal performance of the component under driving load conditions. Furthermore, it is preferred that during the manufacture of the bogie frame, steel inserts made of corrosion-free steel are embedded in the casting profile of the longitudinal beams.

Features of the preferred embodiment variants described herein may also be combined with one another. Thus, even if not described in detail in the embodiments, the present invention includes combinations of different embodiment variations.

The invention also relates to a rail vehicle having a bogie frame according to the invention, which is a cast part made of an aluminium alloy in sand mould casting with a cavity contour.

Drawings

The invention will be further illustrated in the following figures.

Detailed Description

An embodiment of the bogie frame 1 of the present invention is shown in figure 1, which is shown as an integral component of an aluminium casting. It can be seen that the bogie frame 1 of the present invention has two longitudinal beams 3 arranged parallel to each other. The two longitudinal beams 3 are interconnected by means of two transverse beams 2 which are connected to each other. The two transverse beams 2 are in turn interconnected via two central longitudinal bridge pieces 4, which central longitudinal bridge pieces 4 comprise receiving areas 5 for functional elements. Two oppositely disposed projections 7 serving as side stoppers are formed on the two lateral beams 2, respectively.

The fastening means for the functional element to the junction point are provided on the complete assembly, which may be protruding with respect to the surface. Due to the stress flow compatible design, loads and forces can be directed to the interior of the aluminum component in a controlled manner.

In fig. 2 to 4, the cavity profile of the embodiment shown in fig. 1 is shown. The interior of the casting is hollow and consists of one or more cavities 10, which cavities 10 are separated from each other by ribs 9. The beam is composed of longitudinal beams and transverse beams with different designs at the position with special stress. The ribs 9 stabilize the casting, distribute stresses and take on a supporting function.

Fig. 2 shows a side view, in which it can be seen that two longitudinal beams 3 are connected to two transverse beams, on which two oppositely arranged projections 7 as side stops are cast, respectively. The ribs 9 in the interior of the casting together with the outer wall 8 take on the supporting function of the assembly.

Fig. 3 shows a top view of the assembly with the middle cut away. In which the receiving area 5 for the functional element and the longitudinal bridge 4 can be seen. In order to guide the load from the primary suspension, steel bushings 6 are embedded in the assembly (longitudinal beams 3). The steel bushing 6 has a hat shape and uses all the surface area in the assembly to transfer the load level and evenly into the assembly.

Fig. 4 shows the individual ribs 9 in the cavity.

The aluminum casting structure of the present invention is characterized by a significant cost reduction and a simultaneous weight reduction. The driving noise is also greatly reduced. It is possible to dispense with, for example, a truss made of iron and a gas holder made of steel plate, which are troublesome welding works on the steel components. It has considerable advantages over known bogie frames.

Claims

1. Bogie frame (1) for railway vehicles with at least two sets of wheels, comprising two longitudinal beams (3) extending parallel to each other through bearings, one or more transverse beams (2) connected to the longitudinal beams (3) and a receiving area (5) for functional elements, characterized in that the bogie frame (1) is composed of an aluminium alloy with a cavity profile and is integrally formed as a casting, inside which there is a cavity (10) and stabilised through ribs (9), the casting having an elastic surface protection; and a protective area is provided on the underside of the bogie frame (1), on which ribs are cast, between which ribs a rubber layer is provided, which prevent rubble.

2. Bogie frame (1) according to claim 1 characterized in that the aluminium casting is manufactured in sand mould casting.

3. Bogie frame (1) according to claim 1, characterized in that the cavities (10) of both the longitudinal beams (3) and/or the transverse beams (2) are built as gas reserves.

4. Bogie frame (1) according to the previous claim 1 characterized in that the aluminium alloy is composed of aluminium, silicon and magnesium and contains additions of manganese, copper and/or zinc.

5. Bogie frame (1) according to the previous claim 1 characterized in that the casting is uniformly constructed and that both driving stresses and loads are absorbed in the assembly.

6. Bogie frame (1) according to the previous claim 1 characterized in that the force absorption on the main suspension will be supported by the steel bushing (6).

7. Bogie frame (1) according to claim 6, characterized in that a corrosion resistant steel bushing (6) for guiding forces is embedded in the longitudinal beam (3).

8. Bogie frame (1) according to the previous claim 1 characterized in that the rib (9) comprises a load-dependent rib and a transverse rib.

9. Bogie frame (1) according to the previous claim 1, characterized in that the receiving area (5) can be used for accommodating functional elements and intersection points, wherein side stops, rolling bearing fasteners and other fixing elements are cast in functional relation.

10. Bogie frame (1) according to the previous claim 1 characterized in that the two longitudinal beams (3) are connected to the transverse beam (2).

11. Method for manufacturing a bogie frame (1) for a rail vehicle with at least two sets of wheels, comprising two longitudinal beams (3) extending parallel to each other through bearings, one or more transverse beams (2) connected to the longitudinal beams (3) and a receiving area (5) for functional elements, characterized in that the bogie frame (1) is composed of an aluminium alloy with a cavity profile and is integrally formed as a casting with a cavity (10) inside and stabilised by ribs (9), the casting having an elastic surface protection; and a protective area is provided on the underside of the bogie frame (1), on which ribs are cast, between which ribs a rubber layer is provided, which prevent rubble.

12. A method according to claim 11, characterized in that the cavity (10) is made of chemically bonded sand.

13. Method according to any of claims 11 or 12, characterized in that the cavities (10) of the longitudinal beams (3) and/or the transverse beams (2) are constructed as desired in the form of gas reserves.

14. The method of claim 11, wherein the casting is uniformly constructed during the manufacturing process and is subsequently provided with resilient surface protection.

15. Rail vehicle comprising a bogie frame according to any of the preceding claims 1 to 10.